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CFD analysis of a rotary kiln using for plaster production and discussion of the effects of flue gas recirculation application

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Abstract

In this study, the CFD analysis of the rotary kiln is carried out for examining effects of various parameters on energy consumption and efficiency of the rotary kiln. The flue gas recirculation using in many applications is a useful method for combusting of fuel unburned in the flue gas. Also, effects of flue gas recirculation on the combusting of fuel, operating temperature and efficiency of the rotary kiln are discussed in this study. The rotary kiln, which is considered in this study, is used in plaster plant. Two different CFD models were created and these models are compared according to many parameters such as temperature distribution, mixture fraction, the mass fraction of O2, CO, CO and CH4 in the combustion chamber. It is found that the plaster plant has a great potential for an increase in energy efficiency. Results obtained for producers of rotary kiln and burner will be useful for determining better design parameters.

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Abbreviations

C :

Constant

Cp :

Specific heat capacity (kJ/kg∙K)

\( \overrightarrow{F} \) :

Other forces (N)

G u :

Turbulence kinetic energy production rate (velocity)

G b :

Turbulence kinetic energy production rate (buoyancy)

\( \overrightarrow{g} \) :

Gravity (m/s2)

h :

Enthalpy (kJ/kg)

I :

Unit tensor.

i :

i-th content.

P :

Constant pressure (Pa)

Sh :

Radiative heat transfer and combustion rates

u :

Velocity (m/s)

∇ :

Gradient operator

\( \overline{\overline{\tau}} \) :

Stress tensor

ρ :

Density (kg/m3)

Γ:

Diffusion coefficient (m2 / s)

ε :

Rate constant of turbulence kinetic energy (m2/s3)

α :

Turbulence model constant

μ :

Dynamic viscosity (Pa∙s)

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Acknowledgments

This work was supported by the Fırat University Project Support Unit under Grant (TEKF.13.01). Also, the authors are supported by Ar-alçı Company and would like to thank both FUBAP and Ar-alçı Company for their valuable contribution and support to this work.

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Authors and Affiliations

  1. Department of Energy Systems Engineering, Technology Faculty, Fırat University, 23100, Elazig, Turkey

    Mert Gürtürk

  2. Department of Mechanical Engineering, Technology Faculty, Fırat University, 23100, Elazig, Turkey

    Hakan F. Oztop

  3. Department of Mechanical Engineering Education, Universitas Negeri Sebelas Maret, Jl. Ahmad Yani 200A, Pabelan, Indonesia

    Nugroho Agung Pambudi

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  1. Mert Gürtürk
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Correspondence to Mert Gürtürk.

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Gürtürk, M., Oztop, H.F. & Pambudi, N.A. CFD analysis of a rotary kiln using for plaster production and discussion of the effects of flue gas recirculation application. Heat Mass Transfer 54, 2935–2950 (2018). https://doi.org/10.1007/s00231-018-2336-0

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